SLG DUKE DU-201 User manual

OPERATION MANUAL
ELECTRIC WIRE ROPE WINCH
Unit R1D Rockingham Gate
Poplar Way West
Cabot Park, Bristol
BS11 0YW
Contact Us
Tel: [phone]
Fax: [phone]
Email: [e-mail]

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DUKE Electric Wire Rope Winch Introduction
The Duke Electric Wire Rope Winch is designed for building sites, commercial and
domestic, as well as various construction workplaces, such as warehousing, buildings,
storage areas, factories in general, as well as domestic applications.
CONTENTS
1.Preface．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
3
2.Safety Instruction．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
4
2-1.Safety regulations．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
4
2-1-1.General safety rules．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
4
2-1-2.Eiectrical safety rules．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
5
2-1-3.Safety rules of winch．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
6
2-2.Location of warning sign, CE mark, nameplate．．．．．．．．．．．．．．．．．．．．
7
2-3.Checklist of electrical and safety function．．．．．．．．．．．．．．．．．．．．．．
8
3.Electric wire winch Description．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
9
3-1.General characteristics．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
9
3-1-1.Usages．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
9
3-1-2.Features．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
9
3-2.Specifications．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
10
3-3.Overall dimensions．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
11
3-4.Working space required and operating position．．．．．．．．．．．．．．．．．．．．．
12
3-5.Main units and name．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
13
4.Pre-use Preparation．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
14
4-1.Notice and inspection before operation．．．．．．．．．．．．．．．．．．．．．．．．
14
4-1-1.Mechanical check．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
14
4-1-2.Electrical check．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
14
4-2.Expected use and limits of use．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
15
5.Transport and Install．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
16
5-1.Transport．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
16
5-2. Install．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
17
5-2-1.Envirorunent Precautions．．．．．．．．．．．．．．．．．．．．．．．．．．．．
17
5-2-2.Power Cord Insertion．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
17
5-2-3.Mounting．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
18
5-2-4. Continuous rating．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
18
6.Operation．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
19
6-1.Control device:Control panel．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
19
6-2.Operating procedure．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
19
6-3.Handling Precautions．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
20
7.Maintenance and Adjustment．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
21
7-1.Periodical Checking．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
21
7-2.Maintenance．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
22
7-3.Troubleshooting．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
23
8.Drawings and Part list．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
24
8-1.Assembly and part list．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
24
8-2.Electrical system drawings and part list．．．．．．．．．．．．．．．．．．．．．．．．
32

Page 3
Please read this Instruction Manual carefully before you start using the electric
winch. You will find many useful hints which will help you to keep the winch always
in its first-class condition.
You are kindly requested to read this manual thoroughly, to follow scrupulously
the instructions given and for safety reasons, avoid controlling, adjusting or
performing procedures other than those specified.
This winch has been designed and built in full compliance with EN ISO 12100, ISO
14121 and EN 60204 standards on machine and further modification, with
high-quality materials and particularly studying the possibilities to reduce as much
as possible the risks of accident.
Foreword to the operating instructions
The operating instructions are designed to familiarize the user with the winch and
its designated use.
The instruction manual contains important information on how to operate the winch
safety, properly and most efficiently. Observing these instructions helps to avoid
danger, to reduce repair costs and downtimes and to increase the reliability and
life of the winch.
The instruction manual is to be supplemented by the respective national rules and
regulations for accident prevention and environmental protection.
The operating instructions must always be available wherever the winch is in use.
These operating instructions must be applied by any person in change of carrying
out work with and on the winch, such as
operation including setting up, troubleshooting in the course of work, care of
consumables
maintenance (serving, inspection, repair) and/or
transport
This electric winch is designed and built in full compliance with the safety standard,
please read carefully before installing the machine.You will find many hints to keep
the machine in its best condition, also to avoid the risk of accident.
In addition to the operating instructions and to the mandatory rules and regulations
for accident
Prevention and environment protection in the country and place of use of the winch,
the generally recognized technical rules for safe and proper working must also be
observed.
1. Preface

Page 4
2. Safety Instruction
2-1 Safety regulations
2-1-1 General safety rules
1. This electric winch is designed for lifting products only. Do not apply the electric
winch for lifting person.
2. The electric winch should be mounted on a flat solid place.
3. Installing the electric winch at a proper levelling condition to ensure the steel rope
arranged neatly. This may avoid steel rope friction against the winch body due to
regular winding.
4. Make sure your power source comply with the voltage indicated on the electric
winch before connecting the power wires to the power source.
5. Connect the power wires. Tighten the terminals securely.
6. Make sure the electric winch has been properly grounded. The power circuit should
be equipped with an electric shock breaker.
7. Before operating the electric winch, read and follow the instructions for allowable
lifting weight, speed and voltage etc. Indicated on the attached plate.
8. Do not exceed the rated lifting capacity of the electric winch. Allowable lifting
weight is indicated on the attached plate.
9. The electric winch should be operated by a skilled operator. Before operating the
electric winch check again if all lock screws are tightened securely without
loosening.
10. Before operating the electric winch check to see if the steel rope drum runs to the
correct direction and the brake works normally.
11. Do not allow any person approaches under the electric winch, bracket or weight.
12. Select a proper location for mounting the electric winch, to prevent the lifting weight
bumping against any construction, steel frame or construction beam etc while
lifting.
13. Always keep the steel rope in a good condition.When applying the electric winch
for lifting heavy load, keep the steel rope at least 3 turns wounded around the drum.
14. Lift weight vertically. Do not lift weight in a slant or horizontal direction. Do not have
weight hooked on the steel rope for a long time.
15. Do not use the electric winch to pull out any object fixed in the floor or any
construction.
16. When the electric winch is running, keep your hands or any object away from it to
avoid danger.
17. Prevent control wire or power wire from hooking or contacting by the wire rope. This
may avoid electric shock or any danger.
18. In case any malfunction or abnormal noise occurs during operation, stop the electric

Page 5
winch immediately. Check and repair it immediately for safety.
19. Do not alter the electric circuit or use any other replacement parts not supplied from
the original manufacturer.. This avoids affection on the winch performance or any
accident.
20. The operator is requested to fully obey the safety rules listed for safety protection.
2-1-2 Electrical safety rules
1. Before installing, please pay attention to the input rated voltage and current and
make sure the winch is grounded, in order to prevent accident.
2. There must be a main power switch (main breaker) at main input side of electric
control system.
3. Remember to disconnect the main power before repair, maintenance and clean.
4. Unauthorized or untrained personnel cannot repair or maintain any electric
equipment.
5. The keys of electric box and mode select should be conserved by authorized
personnel. Don’t give the key or authorized code to unauthorized personnel.
6. Comply with the maintenance instruction to repair and maintain the electric
equipment.
7. Before operating the winch, check all of the electric equipments and parts are
broken or damaged or not. If there is something broken or damaged, replace a new
one immediately and please note its original rated specification.
8. After connecting power, check the direction of motor rotation and the direction of
winch is correct or not.
9. Please check whether the function of emergency stop button is normal or not. The
emergency stop button is used under emergency situation to cut off power of winch.
(Operator usually misunderstand that the winch is broken down when they forgot to
release the emergency stop button.)
10. Please check whether the function of each safety parts is normal or not, such as
emergency stop button, emergency stop wire, interlocking switch, main power
switch, safety valve, limit switch, and etc.
11. Please check whether the screws of each terminal base are tightened or not. If the
screws loose, screw them tightly.
12. The wiring practices of electric control system must be complied with circuit
diagram.

Page 6
2-1-3 Safety rules of winch
1. Don't misuse the winch, to avoid danger.
2. Before start the winch, make sure all the protecting covers are not breakdown and
damage.
3. If the mechanism or any part breakdown, operator should stop the winch
immediately and then examine and repair it.
4. If it results abnormal sound during operation, operator should stop the winch
immediately and then examine and repair it.
5. If abnormal temperature phenomenon happens during operation, operator should
stop the winch immediately and then examine and repair it.
6. Don’t modify the original design of mechanical structure, in order to keep the best
efficiency and security.
7. Please store the spare parts and tools well, and avoid moist and damage.
8. Untrained or unauthorized operator is prohibited operating, installing or
maintaining winch.
9. Please maintain and repair the winch according to service instruction.
10. Please replace broken part according to the specification in part list.

Page 7
2-2. Location of warning sign, CE mark, nameplate
Electric shock
CE symbol
Nameplate

Page 8
2-3.Checklist of electrical and safety function
Item
Content inspection and safety requirement
Result
Comment
1
Is every terminal protected by isolation plate (IP2X)?
YES
2
Does technician follow the procedure number to wire?
YES
3
Are the diameter of grounding wire and each circuit accord
with safety requirement of designed electrical circuit?
YES
4
Is fuse accord with safety requirement of designed
electrical circuit?
YES
5
Are these screws on electric box fixed tightly?
YES
6
Is the electric box equipped with a ventilator (e.g. fan)?
YES
7
Does the design of electric box conform to IP requirement?
YES
8
Is all the function of every control switch and component
described specifically on this operation manual?
YES
9
Are input voltage, frequency, and phase marked correctly?
YES
10
Is the machine earthed?
YES
11
Is there an independent earth copper plate equipped inside
electric box?
YES
12
Is every function of control device regular?
YES
13
Is the emergency stop device functional?
YES
14
Is the rotary direction of motor or transmission correct?
YES
15
Is the cover functional (fixed or movable)?
YES
16
Is the machine set stable?
YES
17
Have all the acute angle and fur been ground?
YES
18
Has the machine been pasted a CE mark?
YES
19
Has the machine been pasted a nameplate?
YES
20
Has the machine been pasted related warning marks?
YES
21
Have the listed related safety parts in TCF 1.6 been installed
indeed?
YES
22
Have all the safety information and attentions been
provided completely for user?
YES
23
Does the written language of manual and machine conform
to local country?
YES
24
Has the operation manual been provided?
YES
25
Has the EC Declaration of Conformity been signed?
YES

Page 9
3. Electric Wire Winch Description
3-1 General characteristics
3-1-1 Usages
Fit for various workplace applications, such as general factories, warehouse,
construction, plumbing, and agriculture industries. Designed for unique rigging
applications encountered at small venues, lightweight, quiet, and portable. Operates on
1-phase 100V~240V, or 3-phase 220V~380V depends on request.
3-1-2 Features
Braking: designed for both static and dynamic loading. Brake will automatically apply
in the event of power loss.
Gearing: Precision machined gears heat treated for strength and durability, the ball or
needle bearings at all rotating points run in oil bath lubrication for a quieter, smoother
and cooler operation. Planetary gearing for maximum mechanical efficiency.
Motor: Equipped with induction motor, quiet and durable.
Switch: Simply layout of the control with 2M power cable as standard and emergency
stop as option.

Page 10
3-2 Specifications
DU-215
1450
590
520
5000
70
10
12
16
WLL X 1.25
F
40%
240
395
426
DU-214
1350
590
520
3000
70
10
12
14
375
405
DU-3K
1240
400
365
3000
45
10
12
14
193
205
DU-213
1290
590
520
2000
70
10
12
12
364
392
DU-2K
1190
400
365
2000
45
10
12
12
171
183
DU-212
1120
385
340
1000
70
2
12
10
133
145
DU-210
710
310
285
500
45
2
21
8
70
76
DU-223H
675
220
283
350
45
2
38
7
66
71
DU-208
585
201
233
350
45
2
15
6
42
43
DU-205
580
201
233
300
30
2
15
7
38
39
DU-221H
585
201
233
250
30
2
33
7
41
45
DU-204
525
201
201
250
30
2
15
6
35
37
DU-202
520
201
201
200
30
2
15
6
34
36
DU-201
380
190
230
150
25
2
15
5
27
28
Model
Dimensions
Length (mm)
Width (mm)
Height (mm)
Capacity (kg)
Standard Lift(m)
Control Cable(m)
Lifting Speed(m/min)
Wire rope(mm)
Safety Factor
Insulation Class
ED%
No. Of Starts per hr
N..W (kg)
G.W (kg)

Page 11
3-3 Overall dimensions
MODEL
Length(mm)
Width(mm)
Height(mm)
DU-201
380
190
230
DU-202
520
201
233
DU-204
525
201
233
DU-221H
585
201
233
DU-205
580
201
233
DU-208
585
201
233
DU-223H
675
220
283
DU-210
710
310
285
DU-212
1120
385
340
DU-2K
1190
400
365
DU-213
1290
590
520
DU-3K
1240
400
365
DU-214
1350
590
520
DU-215
1450
590
520

Page 12
3-4 Working space required and operating position
FRONT OPERATOR
Top View
1500mm
1500mm
1500mm
1500mm
FRONT OPERATOR

Page 13
3-5 Main units and name
Item
Part’s name
1
Electric Department
2
MOTOR
3
PUSH BUTTON
4
WIRE ROPE
5
GEAR BOX
1
2
3
4
5

Page 14
4-1 Notice and inspection before operation
4-1-1 Mechanical Check
1. Are all transport protection facilities removed?
2. Is there any mechanical damage?
3.Are all the safety device, safety covers refitted from the set-up installation?
4. Are all winch unit correctly aligned and locked in position?
5. Are all mobile and rotating parts exempt of foreign bodies? Is there mobility
unimpaired (tools wire, yarns, waste, etc.)
4-1-2 Electrical Check
1. Are all ground conductors connected?
2. Are all cables connected?
3. Is there any mechanical damage of electrical control operating and indicator units
4. Are all plug-in connection to the winch fitted correctly?
5. Are all the cable near mobile parts fixed correctly?
6. Are the cable fitting tightened?
7.Were wire rests and metal objects removed and cleaned away from switch box,
junction box, control cabinets, and operating panel?
8. Are frequency inverters motor set for the correct V/Hz ratio if applied?
9. Are the drive rotating direction correct?
4. Pre-use Preparation

Page 15
4-2 Expected use and limits of use
Specification of essential parts:
Please refer to the list of specification in operation manual.
This winch is expected to be used under industrial environment:
The well lighting, well ventilation, clean environment, dry, and maintains a normal
temperature (-10°C to +50°C).
The winch needs the following supplies:
Electric power: 1-phase / 240V / 50Hz, or 3-phase / 415V / 50Hz (or base on previous
designation).
Working Duty (ED%):
40%.
No more than 20 minutes use within 60 minutes frame.
The required technique and experience during safety operation and use.
They should be a proficient operator or trained staff.

Page 16
5.Transport and Install
5-1 Transport
Always carry the winch with two hands to prevent a strike.
Below table shows net weight and gross weight for each model of winch.
MODEL
NET WEIGHT (kg)
GROSS WEIGHT (kg)
DU-201
27
28
DU-202
34
36
DU-204
35
37
DU-221H
41
45
DU-205
38
39
DU-208
42
43
DU-223H
66
71
DU-210
70
76
DU-212
133
145
DU-2K
171
183
DU-213
364
392
DU-3K
193
205
DU-214
375
405
DU-215
421
447

Page 17
5-2 Install
5-2-1 Environment Precautions
The following environmental conditions may adversely affect the winch
Low temperature below -10°C
High temperature above 40°C
High humidity conditions above 90%
In organic, chemical, or explosive conditions
In wet weather conditions or snow (Cause rust or short circuit)
In heavy dusty conditions
(Cause malfunction or poor performance)
5-2-2 Power Cord Insertion
Insert the power plug into the power
receptacle of the winch, firmly hand tighten
by turning the locking ring clockwise.
Be sure to lock the cord onto
the holder mounted on the winch.
Do not allow the cords to be tangled
into the wire rope and drum
Determining the appropriate cord based on length required
Grounding
To prevent the risk of electric shock, the power plug must be plugged into a
matching grounded socket.
Switch/Pendant cord connection
Insert the pendant plug into the pendant receptacle of the winch and tighten it by
turning the locking ring clockwise. Be sure to hook the cord on the holder.
To extend the length of the cord connect an extension cord of 15feet max.
Do not exceed 50feet in total

Page 18
5-2-3 Mounting
The winch is designed to be hung or mounted on a firm or stable bar or bracket.
Which ensures the winch doesn’t move from side to side, or swing in a 360°
As an optional accessory the winch Bracket can be purchased.
When hung, do not allow the body or load to be caught by any obstruction.
Be sure to lock the hanger for extra safety
Never hang from the hook only.
This hook is not designed to take a load
5-2-4 Continuous rating
Never use the winch beyond the 20 minutes permitted per hour.
The life of the winch depends on the conditions of the load and working frequency.
During long operating periods make sure to use the winch within its continuous
rating.
Continuous Rating means the amount of allowable usage within one hour which is
35% or 20 minutes per hour or 300 starts per hour.
The maximum number of starts means the number of times the motor starts within
the hour.

Page 19
6. Operation
6-1 Control device: Control panel
6-2 Operating procedure
The person who is untrained or unfamiliar with the operation procedure is prohibited
from operating machine.
Preparation before Working3.Working Me
Check all safety and environmental conditions
Ensure there are a minimum of five(5) wraps of wire wound around the drum
Check the wire rope and discard should there be any signs of excessive wear, too many
broken wires, corrosion, or other defects.
One wire rope consists of 7 strands. One strand has 19 wires. So one of the 7 strands
must not have more than 3 of the 19, damaged wires.
Connect the main power source and ensure grounding.
Do not lift loads exceeding the rated load.
Always use power source at the rated voltage.
Up and Down Control Switch
To Lift a Load. Press ▲Button
To Lower a Load. Press ▼Button

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6-3 Handling Precautions
WARNING
Pay close attention to the following instructions.
Incorrectly operating the winch may result in personal injury or equipment damage.
Never try to lift a load more than the rated capacity
Always remain in control. Never leave a load
Don’t work, walk or stand under and operating winch
Never ride on the hook, sling, or load
A minimum of five (5) wraps of rope around the drum is necessary to support the
rated load
Always look up when working the winch.Watch for overhead danger
Be sure to lift a load vertically. Any slack may allow wire to be tangled.
Prior to lifting make sure the brake is performing correctly.
If any malfunction is detected stop the operation immediately.
Never wrap the load with the wire rope
Wire rope with one or more of the following defects must be replaced immediately.
1. Kink
2. Distortion
3. Corrosion
4. Showing signs of excessive wear or if 1 of the 7 strands has more than 3 of the
19 wires damaged
Do not pull the control pendant to move/pull a load
Do not exceed the continuous rating
Do not rapidly change from Lifting to Lowering
Never work on or weld on a suspended load
Stop operation immediately if the wire rope slackens.
Ensure the slings are fixed in the centre of the swivel hook
Other Important Precautions
Stop operating the winch if there is an abnormal noise or vibration in the gear box.
Do not use the winch or the wire rope as grounding for a welding machine
Make sure the load being lifted is well balanced and secured before commencing.